special field maintenance manual - northern pump manuals/bulletin 130.pdfappendix d- falk™...

Special Field Maintenance Manual for Northern® Pump Model 4800-07-D1761

Bulletin 130REV 2.0

Special Field Maintenance Manual Northern® Pump Model 4800-07-D1761

REVISION 2.0

Northern® Pump

A Division of McNally Industries, LLC

340 West Benson Avenue Grantsburg, WI 54840

Toll Free: 1-800-366-1410 Phone: 715-463-5177

Fax: 715-463-5174 www.northern-pump.com

http://www.nothern-pump.com/


Bulletin 130REV 2.0

Table of Contents

Cautionary Statements ------------------------------------------------------------------------ 2 Required Tools and Equipment ------------------------------------------------------------- 3 Pre-Assembly Instructions ------------------------------------------------------------------- 4 Removal of Pump from Installation -------------------------------------------------------- 6 Pump Disassembly Steps---------------------------------------------------------------------- 9 Inspection ---------------------------------------------------------------------------------------- 17 Pump Assembly -------------------------------------------------------------------------------- 17 Pump Assembly Steps ------------------------------------------------------------------------- 18 Cleanup ------------------------------------------------------------------------------------------ 30 Appendix A – 4800-07-D1761 Pump Unit and Bill of Material Diagram Appendix B –480007D1761 Pump Assembly Bill of Material Diagram Appendix C- D1761 Outline Drawing Appendix D- Falk™ Steelflex® T20 Grid Style Coupling Install & Maint. Manual Appendix E- 4000 Series Pump Troubleshooting Guide

Page 1 of 30


Bulletin 130REV 2.0

Cautionary Statements Failure to heed these cautionary statements may result in personal injury and/or damage to equipment. 1. Disable and lock-out the drive system before any work is done to install, maintain,

or remove the pump. 2. Fully depressurize the entire system. 3. Close the valves closest to the pump in both the suction and discharge pipe. 4. Wear protective eyewear, fire retardant clothing, gloves and any other required face

and head protection. 5. When handling corrosive, caustic, toxic, or hazardous liquids, wear appropriate

protective clothing to prevent contact with skin. 6. Wear protective footwear such as safety shoes. 7. When handling liquids with toxic vapors, wear a properly rated breathing mask. 8. Work area must always be properly ventilated. 9. Work area must be properly grounded. 10. Do not work alone. 11. Clean up any spilled liquid immediately. 12. Consult your company safety policy or program to ensure compliance with all

requirements for work permits, risk assessments, and any additional safety requirements.

Page 2 of 30


Bulletin 130REV 2.0

Required Tools and Equipment 1. Inventory all pump related items. You will need the following to complete the

installation –

Calibrated Torque Wrench capable of measuring 240 foot pounds with a 1.437”

deep well and shallow socket.

Calibrated 0-1” Micrometer, capable of reading increments of .0001”

Grease gun filled with all purpose grease. The recommended grease for use

during assembly and lubricating the mechanical seal support bearing on

Northern® Heavy Duty Gear Pumps is Mobilgrease 28, or comparable synthetic

grease that meets a similar standard.

Snap Ring Pliers with range suitable for 1.375” nominal shaft diameter external

snap ring.

Tool kit containing basic hand tools, wrenches and pliers.

1.437” open end or combination wrench

1.437” box end or combination wrench

Rubber mallet or soft faced dead blow hammer

.500 to .625” diameter brass drive rod measuring at least 12” in length.

Shop towels or rags.

Clean and suitable work surface or bench.

Spill and fire protection equipment.

Genuine factory spare parts kit provided by Northern® Pump

Northern® Bulletin 130- Special Field Maintenance Manual for Northern® Pump

Model 4800-07-D1761

Allen Wrench Set with range of ANSI inch and metric sizes

Page 3 of 30


Bulletin 130REV 2.0

PRE-Assembly Instructions Use of Shall, Will, Should, and May. Shall- Establishes a mandatory requirement to complete this task Will – Establishes a mandatory requirement to complete this task Should – Establishes a recommendation that unless otherwise unattainable, complete task May- Establishes an optional condition to be completed at the discretion of the assembler Use of terms “Tapping”, “Applying Force”, and “Press or Pressing” Tapping- Refers to threading only! Does not mean using a hammer or any other item to

assemble Applying Force – Establishes the use of discretion by the assembler to apply necessary

force required to install, insert, or otherwise assemble components. DOES NOT include the use of a press

Press or Pressing – Allows for the use of a mechanical or Hydraulic Press to insert, install or otherwise assemble components.

Use of the term “Secure” Secure- Refers to placing parts in protective packaging, on a cart, table or other stable

surface until they are required to reassemble. Separation of “Unique” Parts and Assemblies The gears and cylinder shall be considered a “Unique” assembly. This means that once

they are determined to have a dimension that is suitable for the specified side clearance of the pump, they are to remain with that specific assembly. These parts MUST remain separated from other like parts to avoid repeating of steps to re-verify, or even remanufacture parts because of inadvertent mixing. A tagging system should be used by the assemblers to avoid inadvertent mixing of parts.

Use of the term “Contamination” Contamination- Refers to debris, chips, oil, grease, or any other foreign material that may

inadvertently introduced to the Pump Assembly during processing and operations. Great care and judgment will be used to ensure that the cleanliness of the assembly is maintained. This includes covering all parts and the bores of the housing at the close of business for all parts and assemblies

Use of the term “Break Loose” and Tighten Break Loose- Refers to technique of initially loosening bolts of nuts in order to easily

remove fastener at a later disassembly step. Tighten- Refers to a tightening a fastener that does not have a listed torque specification.

This leaves the discretion up to the assembler to use a reasonable and non-excessive amount of force. For all critical fasteners, a torque specification will be listed.

Page 4 of 30


Bulletin 130REV 2.0

PRE-Assembly Instructions Cont…….

Use of the terms to describe locations on Pump Assembly Pump Unit Assembly – See Appendix A for list of parts. Generally it describes the

Pump with Mounting Base, Motor, Coupling, and fasteners. Pump Assembly – See Appendix B for list of parts. Generally it describes the Gear

Pump and it’s internal components.

Top of Pump Assembly

Discharge Flange

Suction Flange

Direction of Rotation Clockwise (CW)

Rear of Pump Assembly

Front of Pump Assembly

Bottom of Pump Assembly

THIS SPACE INTENTIONALLY LEFT BLANK

Page 5 of 30


Bulletin 130REV 2.0

Removal of Pump Assembly from Installation

1. Turn off and lock out the drive mechanism. 2. Fully depressurize both the suction and discharge lines to the pump. 3. Close the valve in the suction and discharge lines closest to the pump. 4. Place a pan or other liquid collecting device under the pump to collect the liquid

that may drain from the pump or the suction and base plate when assembly is disconnected.

5. Remove and secure all suction and discharge piping flange bolts. 6. Proceed to Pump Removal and Disassembly Steps.


Page 6 of 30


Bulletin 130REV 2.0

Step

Pump Removal and Disassembly Steps

Remove Coupling Guard (C) from pump unit assembly by removing 4x (A) socket headed cap screws.

Page 7 of 30

Step Remove Coupling Cover and Grid Assembly (B) by removing socket headed cap screws. (Not Shown in Detail) (See Appendix D) This will allow the pump coupling hub to separate from the motor coupling hub after the mounting brackets are loosened. Secure components and protect grease coated parts from contamination.


Bulletin 130REV 2.0

StepBreak loose but do not remove 2x Outer Jam Nuts (1) and 4x Whole Nuts (2).

Page 8 of 30

StepBreak loose and remove 2x Outer Jam Nuts (1), 2x Mounting Bracket Cap Screws (F), and Rear Mounting Bracket (G). Note – Support the pump weight with a block of wood or suitable substitute.


Bulletin 130REV 2.0

StepBreak loose but do not remove 2x Inner Jam Nuts (1).

StepRemove the 2x Outer Jam Nuts (1). The Pump Assembly is now free from the pump unit base.

Page 9 of 30


Bulletin 130REV 2.0

StepSlide the pump assembly out and off of the front mounting bracket (G) and up away from the motor and unit base. Secure pump assembly on a suitable surface. Use caution as pump assembly is awkward and heavy.

StepRemove the Coupling Hub (D) from the pump assembly by loosening the set screw and pulling the Coupling Hub (D) off of shaft. Secure Drive Key (6)

Page 10 of 30

Set Screw


Bulletin 130REV 2.0

StepRemove 2x Socket Head Cap Screws (3) and 2x Lock Washers (4) from the assembly. Then remove the Bearing & Seat Housing (26) and Gasket (8). The Seal Support Roller Bearing (5) and Mating Ring (7.1) will remain in the Bearing & Seat Housing. Secure as a unique Assembly.

Step Remove the Mechanical Seal (7.2) (Uncompressed) and the spring cup. The Spring Cup will remain resting against the retaining ring and will need to be removed separately.

Page 11 of 30

Spring Cup


Bulletin 130REV 2.0

Reach in through the Packing Plate and remove Retaining Ring from shaft groove with appropriate retaining ring pliers or other suitable tool.

StepRemove the front 2x Whole Nuts (2) and the front 2x Jam Nuts (1). Do not remove the studs (20) & (21) from the assembly at this time. If required, apply force to the studs with mallet to push them back flush with the front surface of the Packing Plate (24)

Step

Page 12 of 30


Bulletin 130REV 2.0

Secure Pump Assembly on a suitable surface or in a vise in an upright position as shown below.

StepLift the packing Plate (24) up and off of the assembly. Secure plate ensuring that the mating surfaces are properly protected.

Step

Page 13 of 30


Bulletin 130REV 2.0

Remove the Bearing Plate (12) and 2x O-Ring (23). 2x Bearing Washer (11.3) and the 2x Bearing Sleeve (11.2) will remain installed in the Bearing Plate (12). They should not need to be replaced. The Rollers (11.1) may fall out of the bearing Plate (12). This is normal.

StepRemove the Front Liner Plate (13). Also remove any O-Rings (23) that were not retained in the Bearing Plate. (12)

Step

Page 14 of 30

Note- Although Bearing Washers (11.3) and Bearing Sleeves have been included in the spare parts provided, they should not need to be replaced. If there are signs of damage, please contact the Northern® Factory for instructions for how to replace bearing sleeves and washers.


Bulletin 130REV 2.0

Remove the Drive Gear and Shaft (14)&(16) and the Driven Gear and Shaft (15)&(17).

Step

Step

Remove the Cylinder (18), 2x 23 O- Rings, and the Rear Liner Plate (19) from the assembly.

Page 15 of 24


Bulletin 130REV 2.0

Remove the Rollers (11.1) and then the Bearing Plate (12) with 2x O-Ring (23). The 2x Bearing Washer (11.3) and the 2x Bearing Sleeve (11.2) will remain installed in the Bearing Plate (12). They should not need to be replaced.

Step

Page 16 of 30

Remove the End Plate (22) from and separate the studs 2x (20) & (21) fromthe 2x Nuts (1) & (2).

Step


Bulletin 130REV 2.0

Inspection 1. Visually inspect all parts for obvious problems- scratches on surfaces that mate with

seals, cracks, upset metal that will affect how parts mate together, burrs, or other serious wear. Correct problem or replace part as necessary.

2. Inspect the cylinder for wear: 5.1 Visually inspect the end surfaces of the cylinder. No nicks, burrs, or scratches

are allowed on the ends of the cylinder. 5.2 Visually inspect the gear bores for any sign that the gear has contacted the

surface of the gear bore. No major nicks, scratches, grooves, or galling is allowed on the gear bore surface. If any of these conditions exist, check the gear outer diameter, shaft bearing diameter, and bearing bore diameter for wear and replace as necessary.

3. Inspect the Packing Plate: 6.1 Visually inspect the seal adapter plate for nicks, scratches, or burrs on the

mating surfaces. No nicks, scratches, or burrs that will affect the mate-up of the parts at assembly or that will affect the ability of the O-ring to properly seal are allowed.

7. Inspect the Bearing & Seat Housing 7.1 Inspect the bearing (5) and bore. No scoring or other abnormal wear patterns

are allowed. If necessary, the bearing may be pressed out of the Bearing & Seat Housing and replaced by pressing in a new one.

Pump Assembly 1. Visually inspect all parts for obvious problems- scratches on surfaces that mate with

seals, cracks, upset metal that will affect how parts mate together, burrs, or other serious wear. Correct problem or replace part as necessary.

2. Proceed to Pump Assembly Steps. Note- Drive shaft & gear should turn freely after completion of assembly.

Page 17 of 30


Bulletin 130REV 2.0

Approx. 1.00” to 1.25”

Approx. .25”

Step

Pump Assembly Steps

Thread 2x Jam Nuts (1) on to 2x Studs (21) and 2x Whole Nut (2) on to 2x Studs (20) as shown below. Set parts aside and secure.

Page 18 of 30

Step

Place End Plate (22) on a suitable and solid surface as shown below.

Note- It is a best practice to alwaysreplace studs and nuts regardless of condition.


Bulletin 130REV 2.0

Step Coat 2x O-Rings (23) with grease. Place 1 O-Ring (23) in groove on the side of the Bearing Plate (12) that will end up facing the rear of the pump (Down). In one smooth motion, place Bearing Plate (12) on top of End Plate (22), ensuring that the O-Ring (23) stays in the groove. Once Bearing Plate (12) is resting on top of the End Plate (22), place second O-Ring (23) in the groove facing the front of the pump (top)

Page 19 of 30

Step Place 16x Rollers (11.1) in each of the bearing Sleeves (11.2) Coat bearings and sleeves with a generous amount of grease to lubricate for start up and to hold in place during assembly.

Note- Once Installed, the inner surface of the liner plate acts as the bearing washer. There is no separate inner Bearing Washer.

Replace all Used Rollers regardless of condition

1 each side

REV 2.0


Bulletin 130REV 2.0

Step Place the Liner Plate Rear (19) on top of the Bearing Plate (12). Verify the orientation of the Liner Plate Rear by the Engraved Text “SUCT REAR”.

Step Coat 2x O-Rings (23) with grease. Place 1 O-Ring (23) in groove on the side of the Cylinder (18) that will end up facing the rear of the pump (Down). In one smooth motion, place Cylinder (18) on top of Rear Liner Plate (19), ensuring that the O-Ring (23) stays in the groove. Once Cylinder (18) is resting on top of the Liner Plate (19), place second O-Ring (23) in the groove facing the front of the pump (top)

Replace used Liner Platesregardless of condition

1 each side

Page 20 of 30


Bulletin 130REV 2.0

Step Place the Drive Shaft & Gear (14)(16) and the Driven Gear & Shaft (15)(17) into the cylinder (18) as shown. Note the orientation. Use grease or clean lube oil to coat the surface of the Liner Plates and all 4 Gear Faces in the areas that they will be riding on both the Front and Rear Liner Plates. Otherwise, grease is also suitable.

Step Place the Liner Plate Front (13) on top of the Cylinder (18). Verify the orientation of the Liner Plate Rear by the Engraved Text “SUCT FRONT”.

Replace used Liner Platesregardless of condition

Page 21 of 30


Bulletin 130REV 2.0

Step On the remaining Bearing Plate (12), place 16x Rollers (11.1) in each of the bearing Sleeves (11.2). Coat bearings and sleeves with a generous amount of grease to lubricate for start up and to hold in place during assembly. Coat an O-Ring (23) with grease. Place O-Ring (23) in groove on this side of the Bearing Plate (12).

In one smooth motion, place Bearing Plate (12) on top of Front Liner Plate (13), ensuring that the O-Ring (23) stays in the groove, and the rollers stay in the sleeves. Once Bearing Plate (12) is resting on top of the Liner Plate(13), place second O-Ring (23) in the groove facing the front of the pump (top)

Step

Replace all Used Rollers regardless of condition

Note- Bearing Washers (11.3) are facing up

after assembly.

Page 22 of 30

REV 2.0


Bulletin 130REV 2.0

Place the Packing Plate(24) on top of the Bearing Plate(12). Step

Insert the pre-assembled Studs (20)(21) and Nuts (1)(2) by pushing through the dowel holes. Gently Slide the pump to the edge of the surface to install the first two Nuts (1) or (2) on the back of the pump. Once the nuts are gently tightened, rotate the pump without lifting to install the other 2x Nuts (1) or (2). Avoiding a lift of the pump will ensure that all the O-Rings (23) stay properly inserted in the grooves.

Step

Page 23 of 30


Bulletin 130REV 2.0

Evenly tighten all both the Whole Nuts (2) and the Jam Nuts (1) until snug. Then evenly Torque to 240 foot pounds.

Step

Step Install the Retaining Ring (9) into the groove on the shaft.

Replace used Retaining Ring regardless of condition

Page 24 of 30


Bulletin 130REV 2.0

StepInsert the Spring Cup over the shaft until it is resting up against the Retaining Ring (9). Next, insert the Seal Assembly.

Spring Cup

Replace used Seal Assembly regardless of condition

Using the Brass Drive Pin or other suitable tool, replace the mating ring by pushing it out of the Bearing and Seat Housing (25). Then Gently replace the Mating Ring by pushing it in with clean fingers. Note- The non-lapped surface will typically have a marker on it to signify it is the NON MATING FACE.

Step

Replace used Mating Ring regardless of condition

The Mating Face will be facing the Mechanical Seal Face.

Lubricate Elastomer with grease before installation

Lubricate O-Ring with grease before installation

Page 25 of 30


Bulletin 130REV 2.0

StepPlace the Gasket (8) over the bore on the Bearing & Seat Housing (25).

StepInstall the Bearing & Seat Housing (25) and Gasket (8) and fasten with 2x Hex Head Cap Screw (3) and 2x Lock Washer (4). There is no torque specification or requirement for this step.

Page 26 of 30


Bulletin 130REV 2.0

StepTurn Drive Shaft (14) and verify Free Rotation of the Pump.

StepInstall the Coupling Hub (D) and Key (6). Tighten Set Screw.

Set Screw

Page 27 of 30


Bulletin 130REV 2.0

Slide the pump assembly into the holes on the Front Mounting Bracket (4). Insert a block of wood or suitable support for the rear of the pump. Use caution as pump assembly is awkward and heavy.

Step

Insert the Rear Mounting Bracket (G) and secure with 2x Hex Head Cap Screws (F). Install and Tighten 2x (1) Jam Nuts.

Step

Page 28 of 30


Bulletin 130REV 2.0

Install and Tighten the 2x Outer Jam Nuts (1). The Pump Assembly is now Secure to the unit base.

Step

Install the Cover & Grid Assembly (B) and the Coupling Guard (C). See Appendix D for instructions.

Step

Page 29 of 30


Bulletin 130REV 2.0

Clean-up 1. Clean all parts of the pump in accordance with your specified cleaning

procedures. Take all appropriate precautions to prevent damage to the parts of the pump during the cleaning process.

2. All pump parts should accept a wide variety of acceptable cleaning methods and

chemicals.


Page 30 of 30

LETTER ITEM NUMBER DESCRIPTION QTY

A 13430004-08 CAP SCREW, HEX HEAD 4B 20820000 COUPLING COVER & GRID ASSEMBLY 1C 7793-4000 GUARD, COUPLING 1D 20821371-06 COUPLING HUB, FALK 80T20 (PUMP) 1E 20822125-08 COUPLING HUB, FALK 80T20 (MOTOR) 1F 13430008-16 CAP SCREW, HEX HEAD 4G 7062-4800 BRACKET, MOUNTING 2H 19210012-32 EYEBOLT, DROP FORGED, 4I 13430010-24 CAP SCREW, HEX HEAD 8J G-1600-13-GA244 BASE, UNIT 1K M7062T MOTOR, ELECTRIC, 40HP 1L 480007D1761 PUMP ASSEMBLY 1

Bulletin 130 REV 2.0Special Field Maintenance Manual for

Northern® Pump Model 4800-07-D1761

APPEDIX APump Unit Assembly Bill of Materials

One O-RingEach Side of (12)

Detail D

Detail B

Bulletin 130 REV 2.0 Special Field Maintenance Manual for


APPEDIX BPump AssemblyBill of Materials

*See Detail ADetail A

*See Detail B

On Plate (12)*See Detail C

On Plate (12)*See Detail C

Detail C Typical 2 Places

One O-RingEach Side of (12)

On Plate (18)*See Detail D

*See Detail A

Page 1 of 2

REV 2.0

Bulletin 130 REV 2.0Special Field Maintenance Manual for


APPEDIX BPump Assembly Bill of Materials

Page 2 of 2

LETTER ITEM NUMBER DESCRIPTION QTY

1 15420014 HEAVY HEX JAM NUT 82 15410014 HEAVY HEX WHOLE NUT 43 13430007-36 CAP SCREW, HEX HEAD 24 11490007 WASHER, LOCK 25 80848 BEARING, ROLLER 16 17500006-40 END KEY 17 6914-4800 ASSEMBLY, MECHANICAL SEAL & 1

7.1 N/A MATING RING 17.2 N/A MECHANICAL SEAL & SPRING SEA 18 1282-4800 GASKET 19 61902 RETAINING RING 1

10 2209-4800 PLATE, PACKING 111 5700-4800-02 ASSEMBLY, ROLLER BEARING 4

11.1 N/A ROLLER, BEARING 6011.2 N/A SLEEVE, BEARING 411.3 N/A BEARING WSHER, OUTER 812 31342-4800 PLATE, BEARING 213 81386-4800-07 LINER PLATE (FRONT) 114 4009-4800-07 SHAFT, DRIVE 115 4081-4800-07 SHAFT, DRIVEN 116 4689-4800-07 PUMP GEAR, HELICAL, L.H. 117 4669-4800-07 PUMP GEAR, HELICAL, R.H. 118 1171-4800-07 CYLINDER, PUMP 119 81387-4800-07 LINER PLATE (REAR) 120 28002-11 STUD, PUMP 221 28002-12 STUD, PUMP 222 3001-4800 PLATE, END 123 19120163-40 O-RING, ROUND SECTIONAL 624 2209-4800 PACKING PLATE 125 57455 NAMEPLATE AND PINS (4) 126 1519-4800 HOUSING, BEARING & SEAT 1NS 56732 GREASE FITTING, STRT,S.S., 1NS 70000-03 WOODRUFF KEY 1

64

17.40

16.68

18.00

3.72

6.51

3.17

11.60

NOTES:

1.0 HYDROSTATIC PRESSURE TEST PUMP HOUSING AT 2653 + 10 PSI FOR 4 HOURS MINIMUM WITH NO EXTERNAL LEAKAGE

1.1 THE TESTED HOUSING SHALL INCLUDE ASSEMBLY OF THE FOLLOWING: PUMP CYLINDER, BEARING PLATE(2), LINER PLATE(2), END PLATE, PACKING PLATE, STUDS(4), WHOLE NUT(4) JAM NUTS (8)

1.2 TEST FLUID- POWER TRANSMISSION FLUID

EQUIV. TO MIL-DTL-17111

1.3 REMOVE ALL RESIDUAL FLUID FROM UNIT UPON COMPLETION OF HYDROSTATIC TEST.

2.0 PAINT ENTIRE UNIT WITH ONE COAT OF SHERWIN WILLIAMS ZINC CLAD II LV INORGANIC ZINC PRIMER OR ZINC CLAD IV ZINC RICH EPOXY PRIMER IN PREPERATION OF THE CUSTOMER APPLICATION OF SYSTEM A OR C, IN ACCORDANCE WITH EXXON MOBIL GLOBAL PRACTICE 29-02-02 (PAINTING GENERAL REQUIREMENTS-OFFSHORE)

49.34

32.00

55.00 REF

8.00

1.50

Z

GREASE BEARINGEVERY 500 HRS.OF OPERATION

.250 NOMINALCOUPLING GAP

900 LB RATEDRING TYPE JOINT

STEEL FLANGESEE DETAIL A

1.00 TYPICAL .75 THRU

4 PLACES

4 PLACESLIFTING HOOKS

15.25 TYP

13.62

1.38TYPICAL

53.00

2.38 TYP1.38 TYP

1.5 NPT LEAD HOLE

3.006.81

7.62

3.00

9.62

32.09

PUMP SUCTION

PUMP DISCHARGE .88 THRU 8 HOLES

8.50

2.00 PORTS 2 PLACES

22.50°

DETAIL Z SCALE 1 : 4

Ø6.50BHC

CRUDE OILS

20-24 GPM

1750 RPM

FLOODDED

40°F - 100°F

1850 PSI

17-37 cP

32 HP (40 HP MOTOR SUPPLIED)

HARDENED ALLOY STEEL

HARDENED ALLOY STEEL

STEEL ROLLER BEARINGS

STEEL W/ IRON INSERT

STEEL W/ D2 WEAR PLATES

ATSM A108 STEEL - SPECIALFLANGED PACKING PLATE

TYPE 21 MECHANICAL SEAL WITHCARBON FACE AND VITON ELASTOMER SST CAGE O-RINGSEAT

900LB. RTJ FLANGES

STEELMOTOR, BASE, COUPLING, GUARD,

STEEL

D

C

B

A

B

C

D

345678

8 7 6 5 4 3 2 1

cNALLYMcNALLY INDUSTRIES, LLC.

THIS DATA IS THE PROPERTY OF NORTHERN PUMP DIVISION OF MCNALLY INDUSTRIES, LLC.AND SHALL NOT BE USED, DUPLICATED, OR DISCLOSED IN WHOLE OR IN PART WITHOUTTHE WRITTEN PERMISSION OF NORTHERNPUMP DIVISION OF MCNALLY INDUSTRIES,LLC.

DWN

CHK

SIZE

DNORTHERN DWG.

SCALE: 1:4 SHEET 1 OF 1

PUMP UNIT ASSEMBLY

4800-07UNIT WT.

CAGE CODE

96953

MET

STD

APVD

FILE NO

1761

2

A340 WEST BENSON AVE, GRANTSBURG, WI 54840 (715)463-8300

1

REVISIONSDESCRIPTION DATE APVDLTR

R. ANTONICH 10/30/09

J. HOFFLAND 11/01/09

MOTOR DATA:

MAKE: BALDORMODEL NUMBER: M7062THORSEPOWER: 40.0RPM: 1750FRAME: 324T POWER SUPPLY: 3 PHASE, 60Hz, 230/460 VENCLOSURE: XPFC

COUPLING DATA:

MAKE: FALKMODEL: 80T20 GRID STYLE W/ VERTICAL SPLIT COVERMAX RPM RATING: 4750 RPMMATERIAL: STEEL WITH STEEL COVER

DRAWING CERTIFIED FOR GCI ROTATING EQUIPMENT - P.O. BOX 83657 - BATON ROUGE, LA 70884CLOCKWISE ROTATION PUMP DESIGN

CUSTOMERPURCHASE ORDER #

L16783

NORTHERN PUMPSALE ORDER #

494143

rantonich

Text Box

APPENDIX C


Bulletin 130REV 2.0

Appendix D

Installation & Maintenance Manual

Falk™ Steelflex® T20 Grid Style Coupling


How To Use This ManualThis manual provides detailed instructions on maintenance,lubrication, installation, and parts identification. Use the tableof contents below to locate required information.

Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Lube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2

Installation & Alignment Instructions. . . . . . . . . . . . Pages 2-4

Annual Maintenance, Relube & Disassembly. . . . . . . . Page 4

Installation & Alignment Data . . . . . . . . . . . . . . . . . . Page 5

Parts Identification & Parts Interchangeability . . . . . . . Page 6

CAREFULLY FOLLOW THE INSTRUCTIONS IN THISMANUAL FOR OPTIMUM PERFORMANCE AND TROUBLEFREE SERVICE.

IntroductionThis manual applies to Sizes 1020T thru 1170T and 20T thru170T20 Falk SteelfIex Tapered Grid Couplings. Unlessotherwise stated, information for Sizes 1020T thru 1170Tapplies to Sizes 20T thru 170T respectively, e.g. 1020T =20T, 1100T = 100T, etc. These couplings are designed tooperate in either the horizontal or vertical position withoutmodification.

CAUTION: Consult applicable local and national safety codesfor proper guarding of rotating members. Observe all safetyrules when installing or servicing couplings. During assembly,seal keyways of vertical couplings to prevent leakage.

WARNING: Lockout starting switch of prime mover and removeall external loads from drive before installing or servicingcouplings.

Lube FittingsDepending on coupling size, cover halves have 1/8 or 3/8 NPTIube holes. Use a standard grease gun and Iube fitting asinstructed on Page 4.

Limited End FloatWhen electric motors, generators, engines, compressors, andother machines are fitted with sleeve or straight rollerbearings, limited axial end float kits are recommended forprotecting the bearings. Falk Steelflex couplings are easilymodified to limit end float; refer to Manual 428-820 forinstructions.

LubricationAdequate lubrication is essential for satisfactory operation.Page 2 provides a list of typical lubricants and specificationsfor general purpose and long term greases. Because of itssuperior lubricating characteristics and low centrifugeproperties, Falk Long Term Grease (LTG) is highly

recommended. Sizes 1020T to 1090T20 are furnished with apre-measured amount of grease for each coupling. Thegrease can be ordered for larger size couplings.

The use of general purpose grease requires re-lubrication ofthe coupling at least annually.

Long Term Grease (LTG)The high centrifugal forces encountered in couplings separatethe base oil and thickener of general purpose greases. Heavythickener, which has no lubrication qualities, accumulatesin the grid-groove area of Steelflex couplings resulting inpremature hub or grid failure unless periodic lubrication cyclesare maintained.

Falk Long Term Grease (LTG) was developed specifically forcouplings. It resists separation of the oil and thickener. Theconsistency of Falk LTG changes with operating conditions. Asmanufactured it is an NLGI #1/2 grade. Working of thelubricant under actual service conditions causes it to becomesemifluid while the grease near the seals will set to a heaviergrade, helping to prevent leakage.

LTG is highly resistant to separation, easily out performing allother lubricants tested. The resistance to separation allows thelubricant to be used for relatively long periods of time.

Steelflex couplings initially lubricated with LTG will not requirere-lubrication until the connected equipment is stopped forservicing. If a coupling leaks grease, is exposed to extremetemperatures, excessive moisture, or experiences frequentreversals, more frequent lubrication may be required.

Although LTG grease is compatible with most other couplinggreases, the mixing of greases may dilute the benefits of LTG.

USDA ApprovalLTG has the United States Department of Agriculture Food Safety& Inspection Service approval for applications where there is nopossibility of contact with edible products. (H-2 ratings).

CAUTION: Do not use LTG in bearings.

Rexnord Industries, LLC, Coupling Group 428-2105555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 March 2003 (9-05 Pdf Revision)

Fax: 262-796-4064 e-mail: [email protected] web: www.rexnord.com Supersedes 11-00

Falk™ Steelflex® Couplings • Installation and Maintenance

Type T20 • Sizes 1020–1170 & 20–170 (Page 1 of 6)

TYPE T20 STEELFLEX COUPLING

Specifications — Falk LTGThe values shown are typical and slight variations arepermissible.

AMBIENT TEMPERATURE RANGE — -20°F (-29°C) to 250°F(121°C). Min. Pump = 20° F (-7° C).

MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @100°F (38°C).

THICKENER — Lithium & soap/polymer.

CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM#D4425 (Centrifuge Test) — K36 = 2/24 max., very highresistance to centrifuging.

NLGI GRADE (ASTM D-217) — 1/2

CONSISTENCY (ASTM D-217) — 60 stroke workedpenetration value in the range of 315 to 360 measured at77°F (25°C)

MINIMUM DROPPING POINT — 350°F (177°C) minimum

MINIMUM TIMKEN O.K. LOAD — 40 lbs.

ADDITIVES — Rust and oxidation inhibitors that do notcorrode steel or swell or deteriorate synthetic seals.

Packaging14 oz (0,4 kg ) CARTRIDGES — Individual or case lots of 10or 30.

35 lb (16 kg )PAIL, 120 lb (54 kg ) KEG & 400 lb (181 kg)DRUMS.

General Purpose GreaseAnnual Lubrication — The following specifications andlubricants for general purpose grease apply to Falk Steelflexcouplings that are lubricated annually and operate withinambient temperatures of 0°F to 150°F (-18°C to 66°C). Fortemperatures beyond this range (see Table 1), refer to Falk.

If a coupling leaks grease, is exposed to extremetemperatures, excessive moisture, or experiences frequentreversals, more frequent lubrication may be required.

Specifications — General Purpose CouplingLubricantsThe values shown are typical and slight variations arepermissible.

DROPPING POINT — 300°F (149°C) or higher.

CONSISTENCY — NLGI No. 2 with 60 stroke workedpenetration value in the range of 250 to 300.

SEPARATION AND RESISTANCE — Low oil separation rateand high resistance to separation from centrifuging.

LIQUID CONSTITUENT — Possess good lubricatingproperties equivalent to a high quality, well refined petroleumoil.

INACTIVE — Must not corrode steel or cause swelling ordeterioration of synthetic seals.

CLEAN — Free from foreign inclusions.

General Purpose Greases Meeting FalkSpecificationsLubricants listed below are typical products only and shouldnot be construed as exclusive recommendations.

Installation Of Type T20 Steelflex TaperedGrid Couplings

InstallationOnly standard mechanics tools, wrenches, a straight edge,and feeler gauges are required to install Falk Steelflexcouplings. Clean all parts using a non-flammable solvent.Check hubs, shafts and keyways for burrs. Coupling Sizes1020T thru 1090T are generally furnished for CLEARANCEFIT with setscrew over the keyway. Sizes 1100T and larger arefurnished for an INTERFERENCE FIT without a setscrew.

CLEARANCE FIT HUBS — Clean all parts using anon-flammable solvent. Check hubs, shafts, and keyways forburrs. Do not heat clearance fit hubs. Install keys, mount hubswith flange face flush with shaft ends or as otherwise specifiedand tighten setscrews.

INTERFERENCE FIT HUBS — Furnished without setscrews. Heathubs to a maximum of 275°F (135°C) using an oven, torch,induction heater, or an oil bath. To prevent seal damage, DONOT heat hubs beyond a maximum temperature of 400°F(205°C).

When an oxy-acetylene or blow torch is used, use an excessacetylene mixture. Mark hubs near the center of their length inseveral places on hub body with a temperature sensitivecrayon, 275°F (135°C) melt temperature. Direct flame towardshub bore using constant motion to avoid overheating an area.

Rexnord Industries, LLC, Coupling Group428-2105555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060March 2003 (9-05 Pdf Revision)

Fax: 262-796-4064 e-mail: [email protected] web: www.rexnord.comSupersedes 11-00

Installation and Maintenance • Falk™ Steelflex® Couplings

(Page 2 of 6) Type T20 • Sizes 1020–1170 & 20–170

TABLE 1 — General Purpose Greases �

Ambient TemperatureRange

0°F to 150°F(-18°C to 66°C)

-30°F to 100°F(-34°C to 38°C)

Manufacturer Lubricant † Lubricant †

Amoco Oil Co. Amolith Grease #2 Amolith Grease #2BP Oil Co. Energrease LS-EP2 Energrease LS-EP1Chevron U.S.A. Inc. Dura-Lith EP2 Dura-Lith EP1Citgo Petroleum Corp. Premium Lithium Grease EP2 Premium Lithium Grease EP1Conoco Inc. EP Conolith Grease #2 EP Conolith Grease #2

Exxon Company, USA Unirex EP2 Unirex EP2E.F. Houghton & Co. Cosmolube 2 Cosmolube 1Imperial Oil Ltd. Unirex EP2 Unirex EP2Kendall Refining Co. Lithium Grease L421 Lithium Grease L421

Keystone Div. (Pennwalt) 81 EP-2 81 EP-1Lyondell Petrochemical(ARCO)

Litholine H EP 2 Grease Litholine H EP 2 Grease

Mobil Oil Corp. Mobilux EP111 Mobilith AW1Petro-Canada Products Multipurpose EP2 Multipurpose EP1

Phillips 66 Co. Philube Blue EP Philube Blue EPShell Oil Co. Alvania Grease 2 Alvania Grease 2Shell Canada Ltd. Alvania Grease 2 Alvania Grease 2Sun Oil Co. Ultra Prestige 2EP Ultra Prestige 2EP

Texaco Lubricants Starplex HD2 Multifak EP2Unocal 76 (East & West) Unoba EP2 Unoba EP2Valvoline Oil Co. Multilube Lithium EP Grease . . .

� Grease application or re-lubrication should be done at temperatures above 20°F(-7°C). If grease must be applied below 20°F (-7°C), consult the Factory.

† Lubricants listed may not be suitable for use in the food processing industry; checkwith lube manufacturer for approved lubricants.

WARNING: If an oil bath is used, the oil must have a flashpoint of 350°F (177°C) or higher. Do not rest hubs on thebottom of the container. Do not use an open flame in acombustible atmosphere or near combustible materials.

Heat hubs as instructed above. Mount hubs as quickly as possiblewith hub face flush with shaft end. Allow hubs to cool beforeproceeding. Insert setscrews (if required) and tighten.

Maximize Performance And LifeThe performance and life of couplings depend largely uponhow you install and maintain them. Before installingcouplings, make certain that foundations of equipment to beconnected meet manufacturers’ requirements. Check for softfoot. The use of stainless steel shims is recommended.Measuring misalignment and positioning equipment withinalignment tolerances is simplified with an alignment computer.These calculations can also be done graphically ormathematically.

Alignment is shown using spacer bar and straight edge. Thispractice has proven to be adequate for many industrialapplications. However, for superior final alignment, the use ofdial indicators (see Manual 458-834 for instructions), lasers,alignment computers, or graphical analysis is recommended.

1— Mount Covers, Seals & Hubs

Lock out starting switch of prime mover. Clean all metal partsusing a non-flammable solvent. Place seals into each cover halfand lightly coat seals with grease. Place covers on shafts BEFOREmounting hubs. Heat interference fit hubs as previously instructed.Seal keyways to prevent leakage. Mount hubs on their respectiveshafts so the hub face is flush with the end of its shaft unlessotherwise indicated. Tighten setscrews when furnished.

2 — Gap & Angular Alignment

Use a spacer bar equal in thickness to the gap specified inTable 2, Page 5. Insert bar as shown below left, to same depthat 90° intervals and measure clearance between bar and hubface with feelers. The difference in minimum and maximummeasurements must not exceed the ANGULAR installationlimits specified in Table 2.

3 — Offset Alignment

Align so that a straight edge rests squarely (or within the limitsspecified in Table 2) on both hubs as shown above and also at90° intervals. Check with feelers. The clearance must notexceed the PARALLEL OFFSET installation limits specified inTable 2. Tighten all foundation bolts and repeat Steps 2 and3. Realign coupling if necessary.

4 — Insert Grid

Insert gasket thru the gap and hang it on either hub. Pack gapand grooves with specified lubricant before inserting grid. Whengrids are furnished in two or more segments, install them so thatall cut ends extend in the same direction (as detailed in theexploded view picture above); this will assure correct grid contactwith non-rotating pin in cover halves. Spread the grid slightly topass over the coupling teeth and seat with a soft mallet.





5 — Pack With Grease & Assemble Covers

Pack the spaces between and around the grid with as muchlubricant as possible and wipe off excess flush with top of grid.Make certain lube plugs are removed to ease in coverassembly. Slide cover halves with seals onto hubs and positionwith lube holes 180° apart (90° apart for Sizes 1150 thru1170). Line up cover and gasket bolt holes and secure withfasteners; tighten to torque specified in Table 2. CAUTION:

Make certain lube plugs are installed before operating.

Annual MaintenanceFor extreme or unusual operating conditions, check couplingmore frequently.

1. Check alignment per steps on Page 3. If the maximumoperating misalignment limits are exceeded, realign thecoupling to the recommended installation limits. See Table2 for installation and operating alignment limits.

2. Check tightening torques of all fasteners.

3. Inspect seal ring and gasket to determine if replacement isrequired. If leaking grease, replace.

4. When connected equipment is serviced, disassemble thecoupling and inspect for wear. Replace worn parts. Cleangrease from coupling and repack with new grease. Installcoupling using new gasket as instructed in this manual.

Periodic Lubrication

The required frequency of lubrication is directly related to the typeof lubricant chosen, and the operating conditions. Steelflexcouplings lubricated with common industrial lubricants, such asthose shown in Table 1, should be relubed annually. The use ofFalk Long Term Grease (LTG) will allow relube intervals to beextended to beyond five years. When relubing, remove both lubeplugs and insert lube fitting. Fill with recommended lubricant untilan excess appears at the opposite hole. CAUTION: Makecertain all plugs have been inserted after lubricating.

Coupling Disassembly & Grid Removal

Whenever it is necessary to disconnect the coupling, removethe cover halves and grid. A round rod or screwdriver that willconveniently fit into the open loop ends of the grid is required.Begin at the open end of the grid section and insert the rod orscrewdriver into the loop ends. Use the teeth adjacent to eachloop as a fulcrum and pry the grid out radially in even,gradual stages, proceeding alternately from side to side.





Type T Coupling Installation & AlignmentDataMaximum life and minimum maintenance for the coupling andconnected machinery will result if couplings are accuratelyaligned. Coupling life expectancy between initial alignmentand maximum operating limits is a function of load, speedand lubrication. Maximum operating values listed in Table 2are based on cataloged allowable rpm.

Values listed are based upon the use of the gaps listed,standard coupling components, standard assemblies, andcataloged allowable speeds.

Values may be combined for an installation or operating condition.

Example: 1060T max. operating misalignment is .016"parallel plus .018" angular.

NOTE: For applications requiring greater misalignment, referapplication details to the Factory.

Angular misalignment is dimension X minus Y as illustrated below.

Parallel misalignment is distance P between the hub centerlines as illustrated below.

End float (with zero angular and parallel misalignment) is the axialmovement of the hubs(s) within the cover(s) measured from “O” gap.





GAP

Y

X

F F

ANGULAR MISALIGNMENT

P

P

PARALLEL OFFSET MISALIGNMENT END FLOAT

TABLE 2 — Misalignment & End Float

SIZE

Installation Limits Operating LimitsCover Fastener

TighteningTorque Values

AllowSpeed(rpm)

Lube WtParallelOffset-P

Angular(x-y)

Hub Gap� 10%

ParallelOffset-P

Angular(x-y)

End FloatPhysical Limit

(Min) 2 x F

MaxInch

Maxmm

MaxInch

Maxmm

Inch mmMaxInch

Maxmm

MaxInch

Maxmm

Inch mm (lb-in) (Nm) lb kg

1020T .006 0,15 .003 0,08 .125 3 .012 0,30 .010 0,25 .186 4,72 100 11,3 6000 .06 0,031030T .006 0,15 .003 0,08 .125 3 .012 0,30 .012 0,30 .186 4,72 100 11,3 6000 .09 0,041040T .006 0,15 .003 0,08 .125 3 .012 0,30 .013 0,33 .186 4,72 100 11,3 6000 .12 0,051050T .008 0,20 .004 0,10 .125 3 .016 0,41 .016 0,41 .186 4,72 200 23,6 6000 .15 0,07

1060T .008 0,20 .005 0,13 .125 3 .016 0,41 .018 0,46 .220 5,59 200 22,6 6000 .19 0,091070T .008 0,20 .005 0,13 .125 3 .016 0,41 .020 0,51 .220 5,59 200 22,6 5500 .25 0,111080T .008 0,20 .006 0,15 .125 3 .016 0,41 .024 0,61 .282 7,16 200 22,6 4750 .38 0,171090T .008 0,20 .007 0,18 .125 3 .016 0,41 .028 0,71 .282 7,16 200 22,6 4000 .56 0,25

1100T .010 0,25 .008 0,20 .188 5 .020 0,51 .033 0,84 .408 10,36 260 29,4 3250 .94 0,431110T .010 0,25 .009 0,23 .188 5 .020 0,51 .036 0,91 .408 10,36 260 29,4 3000 1.1 0,511120T .011 0,28 .010 0,25 .250 6 .022 0,56 .040 1,02 .546 13,87 260 29,4 2700 1.6 0,741130T .011 0,28 .012 0,30 .250 6 .022 0,56 .047 1,19 .548 13,92 650 73,4 2400 2.0 0,91

1140T .011 0,28 .013 0,33 .250 6 .022 0,56 .053 1,35 .568 14,43 650 73,4 2200 2.5 1,141150T .012 0,30 .016 0,41 .250 6 .024 0,61 .062 1,57 .620 15,75 650 146 2000 4.2 1,911160T .012 0,30 .018 0,46 .250 6 .024 0,61 .070 1,78 .630 16,00 1300 146 1750 6.2 2,811170T .012 0,30 .020 0,51 .250 6 .024 0,61 .079 2,01 .630 16,00 1300 146 1600 7.7 3,49

Parts IdentificationAll coupling parts have identifying part numbers as shownbelow. Parts 3 and 4 (Hubs and Grids), are the same for bothType T10 and T20 couplings. All other coupling parts are unique toType T20. When ordering parts, always SPECIFY SIZE and TYPEshown on the COVER.

Parts InterchangeabilityParts are interchangeable between Sizes 20T and 1020T, 30Tand 1030T, etc. except as noted.

GRIDS — Size 1020T thru 1140T Steelflex couplings use bluegrids or non-painted grids. Older models, 20T thru 140T, useorange grids.

CAUTION: Blue grids may be used in all applications, but DONOT substitute orange grids for blue.





PART DESCRIPTION1. Seal (T20)

2. Cover (T20)

3. Hub (Specify boreand keyway)

4. Grid

5. Gasket (T20)

6. Fasteners (T20) — Couplingmay be supplied with oneset each of inch seriesfasteners and metricfasteners.

7. Lube Plug

ORDER INFORMATION1. Identify part(s) required by

name above.

2. Furnish the followinginformation.

EXAMPLE:Coupling Size: 1030Coupling Type: T20Model: BBore: 1.375Keyway: .375 x .187

3. Price parts from appropriateprice list and discount sheet.

PART NUMBER LOCATION

SIZESIZE &PARTNUMBER

SIZE, PART NUMBER& BORE

1

23 4

3

5 2

1

6

7


Bulletin 130REV 2.0

Appendix E

Trouble Shooting Guide (Standard for all 4000 series pumps)

Problem Solution Key will not fit into keyway in drive shaft

Check for burrs and nicks in the keyway and on the key. Remove as required. Measure width of key and keyway, if an interference fit is found, reduce the width of the key.

Motor shaft turns but pump shaft does not Verify that the coupling has been properly

installed with the correct key in each hub. Verify that the set screws are properly tightened in each coupling hub.

Pump will not prime

Check for air leaks in the suction line. Check for correct rotation of the pump shaft -- CW when facing the shaft end of the pump. “Wet” the internals of the pump with the liquid to be pumped to provide a liquid hydraulic seal in the pumping chamber. Make sure that all suction and discharge line valves are open. Make sure that the suction and discharge lines are free of obstructions.

APPENDIX E Page 1 of 2


Bulletin 130REV 2.0

Problem Solution Pump requires too much torque

Make sure that the viscosity of the liquid being pumped is not abnormally high. Check alignment of pump.

Pumped liquid has entrained air

Check for air leaks in suction line.

Flow rate is too low

Make sure that the viscosity of the liquid being pumped is not abnormally low. Make sure that the discharge pressure is not abnormally high. Make sure that there are no air leaks in the suction line. Verify that the rotational speed is correct. Disassemble pump and verify that the internal clearances are within specification.

APPENDIX E Page 2 of 2

special field maintenance manual - northern pump manuals/bulletin 130.pdfappendix d- falk™...

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